railway engineering

1. Basics about Rails and
Sleepers
By
(N.R. Kale )
AXEN/IRICEN

2. Different types of rails
Double headed rails
Bull headed rails
Flat footed rails

3. Brand marks
Brand mark shall include:
• Rail section
• The Grade of steel
• Identification mark of manufacturer
• Month (using Roman numbers) and last
two digits of year of manufacture
• Process of making
(O –Basic oxygen or E- electric)
(Brand mark will be rolled at every 3.0m)

4. Grade of steel (As per T-12/09)
Grade of steel Mark on Rail
880 880
1080 HH 1080 HH
1080 Cr 1080 CR
880 Cu-Mo 880 CM
880 Ni Cr Cu 880 NC
880 Vanadium 880 VN
880 Niobium 880 NB

5. Standard length and Identification for new
Rails (As per T-12/09)
S.N. Length of Rail Colour code on each end
face on web
1 13m,26m,130m
and 260m
Yellow
2 12m,25m,129m
and 259m
Blue
3 11m & 24m White
4 10m Green

6. Rail Section of rails as per T-12/09
Sr.No. Rail Section Calculated
Weight (Kg/m)
1 IRS 52 kg/m 51.89
2 UIC 60 kg/m 60.34
3 ZU 1-60 PROFILE 73.00
4 136 RE (68 kg/m) 67.364

7. Main Dimensions of Rails
Rail
Section
Wt/M
(Kg)
Height
(mm)
Flange
Width
(mm)
Head
Width
(mm)
Web
Thickness
(mm)
60Kg 60.34 172 150 74.3 16.5
52Kg 51.89 156 136 67 15.5
90R 44.61 142.9 136.5 66.7 13.7

8. Quality of Rails (C.S.No-117)
 Prime Quality Rails: New Rail as per IRS-T-12/09( Its
latest version). These rails are further classified based on
tolerance in end straightness as under-
 Class ‘A’ Rails
 Class ‘B’ Rails
 ‘Industrial Use Rails’ : Rails with relaxation in sectional
tolerance as provided in Amendment to IRS – T-12/09 but
otherwise conforming to
T-12/09 in all other respects i.e. Chemical composition,
mechanical properties etc.
These rails can be used in Industrial siding with speed
restriction of 50 Kmph

9. Identification of different qualities of
Rails (As per T-12/09)
Class ‘A’ Rail Green paint on gauge/non gauge
face for a distance of 500mm at
each end
Class ‘B’ Rail No paint mark
‘IU’ Rail 1.Blue paint on both sides end
face of flange for a distance of 500
mm from each end.
2.The letter ‘IU’ shall be stamped
in 15mm size on end faces

10. Standard sections of Rails
(CS-117 dated 19.05.09)
Track Renewal and doubling 60Kg
All gauge conversion and new line
construction <5 GMT route and not defined
as mineral route
52 Kg
All gauge conversion and new line
construction >5 GMT route
60 Kg
Minimum UTS of above rails shall be – 90 UTS

11. Contd. …..
Loop Lines 60 Kg S/H or
52 Kg S/H
New Rails may be used in loop lines on A, B, C
route with prior approval of Board
Private and other siding with
permissible speed up to 50 Kmph
52 Kg S/H or
52 Kg ‘IU’
Private and other siding with
permissible speed > 50 Kmph
60 Kg

12. Rail Closure (Para-256)
 A rail piece of less than the standard length,
used in the track for closing a rail gap, is called
rail closure. The shortest length of rail closure to
be used in the track as a permanent measure is
5.50 m.
 On following locations and 500m approaches on
both side, minimum length of closure is 11m.
Tunnel, Deep cutting, Major & Important bridges
and high embankment

13. Guide lines for using closure
Limited use.
Only hacksaw cut, no gas cut.
Avoid on junction of different types of rails
and/or sleepers.
Avoid on bridges, level crossings and
points and crossings.
Better not to use opposite to each other.

14. Causes of Rail Deterioration
(Para- 249)
1) Corrosion and rusting (Generally noticed on
web & foot of rail)
Locations Prone to corrosion :
i) Platform lines.
ii) Sidings where corrosive goods are dealt.
iii) Tunnels and damp cuttings.
iv) Coastal area.
v) Industrial belts.

15. Contd. …
2.Wear on Rail Table :
 Normally of very small order.
 Amount of wear increases with heavy
traffic density as in suburban section.
3. Flattening of rail table:
 Mostly occurs on the inner rail of a curve.
 Indication of over loading

16. Contd. …
4. Wear on Gauge Face:
Noticed on outer rail of a curve.
Due to heavy pressure from the wheels
which results in the running edge
becoming worn or ‘side-cut’.
Specially in suburban sections where
multiple unit coaches are provided.

17. Contd. …
5. Hogging of Rail Ends:
A hogged rail is one with its end or ends
bent in vertical direction.
Due to bad maintenance of joints.
Due to unserviceable sleepers on joints.

18. Contd. …
6. Battering of Rail Ends:
Occurs where the gap on fish plated joints
are excessive.
Caused by impact of wheels on end of a
rail particularly if the fishplates do not fit
snugly.

19. Maintenance of joints (Para 251)
The efficient maintenance depends on:
a. Efficiency of fastening
b. Correct spacing of joint sleeper and
efficient packing.
c. Correct expansion joint.
d. Proper lubrication.
e. Correct maintenance of gauge &
X/Level
f. Efficient drainage.

20. Contd. …
7.Wheel burns:
Wheel slipping occurs usually on adverse
gradient or while starting on raising
gradient.
Heat is generated and depression is
caused on rail table known as wheel
burns.
Also occur due to sudden application of
brakes.

21. Contd. …
8.Corrugation:
o Rail table develops hollows and ridges.
o Also known as “Roaring rails”.
o Excessive vibrations are caused.
o Fastening and packing tends to get loose.
o Track needs frequent attention.

22. Permissible Wear on Rails
(Para-302)
Vertical Wear
Rail Section Vertical Wear
(mm)
60 Kg 13.00
52 Kg 8.00
90 R 5.00

23. Contd. ….
Lateral Wear
Section Route Lateral Wear
Curves A & B Route
C & D Route
8.00 mm
10.00 mm
Straight A & B Route
C & D Route
6.00 mm
8.00 mm

24. Service Life of Rails
Rail Section T-12
MM Rail
90 UTS Rail
60 Kg 550 GMT 800 GMT
52Kg 350 GMT 525 GMT
90 R 250 GMT -

25. Various Types of Fish plates and
Their usage
a) Ordinary fishplate : Used in normal
cases.
b) 1 m long fishplate : Used for repairs to
rail fracture, Laying of LWR etc.
c) Joggled fish plate : Used to protect
defective / fractured weld.
d) Combination fishplate : Used to join
different section of rails

26. Contd. …
e) Collarless F/plate : Used under lock bar
on stock rail joint. Top collar of inside fish
plate is trimmed. However, trimming of top
collar is not required in case of 60 Kg rails.
f) Skimmed fish plate : Used in insulated
block joints.
g) Slotted fish plate : Used in case of rail
failure.

27. Drilling of holes in rails
The position of hole in rail is at a specified
distance from the base of the rail and not
in the centre of the web.
 the proper drilling of a hole should be
ensured by making use of template.
 Punch should be used for making the hole
centres on the web.
The permissible tolerance is only 0.8mm

28. Drilling of holes in rails
Rail Section Distance of hole centre
from bottom of rail
60 Kg 76.25 mm
52 Kg 66.50 mm
90 R 60.00 mm
75 R 54.00 mm

29. Chamfering of bolt holes
For hardening of periphery of holes and
thereby delays the formation of star
cracks.
Existing bolt holes in fracture prone zone
should be chamfered.
Elongated holes should not be chamfered
to avoid uneven hardening.

30. Drilling of holes in rails
S.No
.
location Dia of hole
1 Ordinary rail hole at F.P.Joint 32 mm
2 Adjoining rail of CMS
Crossing
26.5 mm
3 Glued joints 30 mm
4 Check rail hole 27/28 mm
5 Holes in Tongue rail for fixing
stretcher bar
18/20 mm
6 Stock rail hole for slide chairs 28 mm

31. Laying of Sleepers (Para-244)
Sleepers shall be laid square to rails on
straight and radially on curve.
The sleeper spacing should be marked on
outer rail in case of curved track.
Closer spacing should be provided at joint
sleepers of fish plated joints and between
joint sleeper and shoulder sleeper.

32. Sleeper density
The sleeper density is the number of
sleepers used per rail length.
Described as M+1, M+2, M+3 etc. Where
M is the length of standard rail in meters.
In case of LWR/CWR, this is expressed in
number of sleeper per Km of track.
Sleeper density depends upon max.
permissible speed and traffic density.

33. Spacing of sleeper (Maximum)
Spacing Centre to Centre spacing in Cms
Wooden sleeper Metal sleeper
B.G M.G B.G. M.G.
Bet. Joint sleeper 30 25 38 33
Bet Jt. Sleeper/1st
Shoulder sleeper
61 58 61 58
Bet. 1st/2nd
shoulder sleeper
Spacing to be value bet. 2 and 4
Bet. Intermediate
sleeper
To be equal and whole number of
cm.

34. Correction slip no.102 dated 29.05.07
Where concrete sleepers are required to
be laid in unavoidable circumstances, in
SWR track the sleeper spacing,
including at fish plated joint, shall be
kept uniform, in addition, 1M long fish
plates, be provided at joint.

35. Minimum Sleeper density
(CS No-117 dated 19.05.09)
All CTR, TSR, Gauge conversion,
Doubling, New line construction
1660 nos/km
Loop lines of A, B, and C route and
in case of LWR track on any route.
1540 nos/km
Loop lines of other routes in temp.
zone I and II (other than LWR)
1340 nos/km
Loop lines of other routes in temp.
zone III and IV
1540 nos/km

36. Minimum Sleeper density in sidings
(CS-117 dated 19.05.09)
Private and other Sidings with
permissible speed up to 50 Kmph zone
I and II
1340
nos/km
Private and other Sidings with
permissible speed up to 50 Kmph zone
III and IV and in case of LWR track
1540
nos/km
Private and other Sidings with
permissible speed >50 Kmph
1660
nos/km

37. Types of Sleepers
 Wooden Sleepers
 Cast Iron Sleepers
 Steel Sleepers
 Concrete Sleepers

38. Advantages/Disadvantages of
wooden Sleepers
Advantages
i) Easy to manufacture and handling.
ii) Suitable for track circuited area.
iii) Can be used with or without ballast.
iv) Suitable for bridges, Points/Crossings.
v) Suitable for gaunteletted track.
vi) Alignment can be easily corrected.

39. Contd. …
Disadvantages:
i) Lesser life.
ii) Liable to damage by beater packing.
iii) Difficult to maintain the gauge.
iv) Susceptible to fire hazards.

40. Contd. …
Inspection of Sleeper
Sleeper register.
Wooden sleeper more than 5 year.
Category I- Requiring renewal during the
year. Painted with two white lines
Category II- Requiring reconditioning,
painted with one white lines.
Test check by ADEN-50 sleeper/km

41. Number of Screw/Spike per Rail seat
(Para 245/6)
Joint sleepers, Bridge timbers turn
out sleepers
Four
Intermediate sleepers on curves on
other than branch lines
Three
Intermediate sleepers on curve on
branch lines and on straight
Two

42. Use of Bearing Plates
(Para 245/5)
‘T’ Category sleepers
Girder Bridges
Turn outs
Ash pits and examination pits
Joint sleepers
On sharp curve of radius less than 600 m
on B.G. and M.G.

43. Cast Iron Sleepers (Para 246)
Type of Cast Iron Sleepers:
A) C. I. Pot Sleepers
B) C S T- 9 Sleepers
Advantages of Cast Iron Sleepers:
i) Lesser corrosion.
ii) Easy handling due to light weight.
iii) Higher Scrap value.

44. Contd. …
Disadvantages of Cast Iron Sleepers:
i) Not suitable for high speed route.
ii) Difficult to maintain the Gauge.
iii) Lesser lateral stability.
iv) Not fit for track circuited area.
v) Not suitable for mechanical
maintenance.
vi) Tie bars weakened by corrosion.

45. Usual defects in CST-9 Sleepers
Cracks at rail seats or fracture
Wear of lug and rail seat
Tie bars weakened by corrosion, broken or
damaged by falling of wagon parts.
Corrosion of tie bars inside the cast iron
plates.

46. Steel trough Sleepers
Types of S.T. Sleepers
i) ST sleepers with Pressed up lugs.
ii) ST Sleepers with loose jaws.
iii) Bolt and clip type ST Sleepers.
iv) Special ST Sleepers for Turn out.
v) ST Sleepers with pad plates for use with
elastic rail clip.

47. Usual defects in ST Sleepers
(Para 247)
Rusted and corroded metal
Cracks at rail seat or near the lugs
Elongation of holes
Inspection of sleepers- Over 20 years old
Reconditioning of sleeper

48. Concrete Sleepers & Fastenings
Types of concrete Sleepers:
i)Mono-block Prestressed Concrete
Sleepers.
a) RT 2495 for 52 Kg Rails
b) RT 2496 for 60 Kg Rails
ii) Two block reinforced concrete Sleepers.

49. Contd. …
Advantages of concrete Sleepers:
i) Greater stability.
ii) Track geometry maintained for much.
longer duration hence economical.
iii) Best suited for machine maintenance.
iv) Suitable for Track circuiting area.

50. Contd. …
v) No chances of damage by fire/ corrosion
vi) No possibility of theft.
vii) No chances of gauge widening.
viii) 60 Kg Sleeper can be used for 52 Kg
rail.
ix) Best suited for LWR track.
x) Best performance on P & C, S.E.J.
Guard rails , Level Crossings, Check rail in
curve.

51. Contd. …
Disadvantage :
i) Handling and laying is difficult being
heavy.
ii) Damage is very heavy in case of
derailment.
iii) No scrap value.
iv) Not suitable for manual packing.

52. Contd. …
Conditions for laying Concrete Sleepers:
i) Track should be deep screened.
ii) Cuttings having rocky bed should have
clean ballast cushion of at least 300 mm.
iii)On Arch bridges formation cover min. 1 m.
iv) On other bridges ballast cushion not less
than 300 mm.

53. Elastic Fastenings
Grooved rubber pads:
 Provided between rails and sleepers.
It absorbs the shock.
Resists lateral movement of the rail.
Prevents abrasion of the bottom surface of
rail.
 Laid in such a way that grooves are
parallel to rail .

54. Elastic Rail clip (Pandrol Clip)
Made from Spring Steel bar of 20.6 mm.
Toe Load 900Kg to 1100 Kg (MKIII).
On Fish plated Joint ‘J’ Clip can be used.
Can be driven with ordinary 4 lbs hammer.
Can be fixed on wooden,Steel, and Cast
Iron Sleepers with Special arrangement.

55. Contd. …
Liners :
i) Metal Liners – Provided on Non track
circuited Areas.
ii) Insulated Liners- Provided on Track
circuited areas.
Most commonly used is GFN Liner

56. Different types of Liners used in
Track
S.N
o
Sleeper Rail Metal Liner
1 60Kg 60Kg T-3740
2 60Kg 52Kg T-3741/T-3742
3 52Kg 52Kg T-3738

57. Contd. …
S.No. Sleeper Rail GFN Liner
1 60Kg 60Kg T-3706
2 60Kg 52Kg T-3707/T3708
3 52Kg 52Kg T-3702

58. THANKS

59. Different types of Rails
D/headed Bull headed Flat footed

61. Measurement of Hogged Joint

62. Measurement of Battered Joint

65. Combination fishplates

66. Chamfering tool

67. Rail Screw/Plate Screw

68. Canted Bearing Plate

73. EVOLUTION OF IRS T12
SPECIFICATIONS
FIRST ISSUE IRS T12/36 IN 1936
REVISIONS
IRS T12/39 IRS T12/50
IRS T12/53 IRS T12/55
IRS T12/60 IRS T12/64
IRS T12/88 IRS T12/96
IRS T12/09